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indirect gas-fired indoor power vented make-up air units
Model without Cooling Coil Cabinet
Model with Cooling Coil Cabinet
WARNING
1. Improper installation, adjustment, alteration,
service or maintenance can cause property
damage, injury or death, and could cause
exposure to substances which have been
determined by various state agencies
to cause cancer, birth defects or other
reproductive harm. Read the installation,
operating and maintenance instructions
thoroughly before installing or servicing this
equipment.
2. To prevent premature heat exchanger failure,
do not locate ANY gas-fired appliances
in areas where corrosive vapors (i.e.
chlorinated, halogenated or acid) are present
in the atmosphere.
AVERTISSEMENT
1. Une installation, un réglage, une altération,
une réparation ou une maintenance
impropre risque de causer des dommages,
des blessures ou la mort, et d'engendrer
une exposition à des substances dont
certains États ont déterminé qu'elles
étaient cancérogènes ou pouvaient causer
des malformations à la naissance et des
problèmes de reproduction. Lisez bien les
instructions d'installation, d'utilisation et de
maintenance avant d'installer ou de réparer
cet appareil.
PLEASE BE SURE TO LEAVE IT WITH THE OWNER WHEN YOU LEAVE THE JOB.
INSTALLATION AND SERVICE MANUAL
THIS MANUAL IS THE PROPERTY OF THE OWNER.
Models Approved For Use In California By The CEC
AVERTISSEMENT
2. Pour éviter la panne prématurée de
l'échangeur thermique, ne placez AUCUN
appareil à gaz à des endroits où les vapeurs
corrosives (chlorées, halogénées ou acides)
sont présentes dans l'atmosphère.
.
FOR YOUR SAFETY
IF YOU SMELL GAS:
1. Open windows.
2. Do not try to light any appliance.
3. Don't touch electrical switches.
4. Extinguish any open flame.
5. Immediately call your gas supplier.
POUR VOTR E SÉCURITÉ
Si vous sentez une odeur de gaz:
1. Ouvrez les fenêtres.
2. Ne tentez d'allumer aucun autre appareil.
3. Ne touchez pas aux interrupteurs
électriques.
4. Éteignez toute flamme nue.
5. Appelez immédiatement votre compagnie de
gaz.
5-565.6
5H0806440001
December, 2023
Models DBP/DCP
IBP/ICP
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Table of Contents
Related Manuals for Modine Manufacturing DBG
Summary of Contents for Modine Manufacturing DBG
- Page 1 5-565.6 5H0806440001 December, 2023 INSTALLATION AND SERVICE MANUAL indirect gas-fired indoor power vented make-up air units Models DBP/DCP IBP/ICP Model without Cooling Coil Cabinet Models Approved For Use In California By The CEC AVERTISSEMENT 2. Pour éviter la panne prématurée de l’échangeur thermique, ne placez AUCUN Model with Cooling Coil Cabinet appareil à...
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Page 2: Table Of Contents
INSPECTION ON ARRIVAL FOR YOUR SAFETY Inspect unit upon arrival. In case of damage, report it immediately to transportation company and your local The use and storage of gasoline or other factory sales representative. flammable vapors and liquids in open Check rating plate on unit to verify that power supply meets containers in the vicinity of this appliance is available electric power at the point of installation. -
Page 3: Special Precautions
SPECIAL PRECAUTIONS SPECIAL PRECAUTIONS WARNING THE INSTALLATION AND MAINTENANCE INSTRUCTIONS IN THIS MANUAL MUST BE FOLLOWED TO PROVIDE 1. To prevent premature heat exchanger failure, do not locate SAFE, EFFICIENT, AND TROUBLE-FREE OPERATION. IN ANY gas-fired appliances in areas where corrosive vapors ADDITION, PARTICULAR CARE MUST BE EXERCISED (i.e. - Page 4 SPECIAL PRECAUTIONS AVERTISSEMENT CAUTION 1. Pour éviter la panne prématurée de l’échangeur thermique, 1. Purging of air from gas supply line should be performed ne placez AUCUN appareil à gaz à des endroits où les as described in ANSI Z223.1 - latest edition “National Fuel vapeurs corrosives (chlorées, halogénées ou acides) sont Gas Code”, or in Canada in CAN/CGA-B149 codes.
- Page 5 SPECIAL PRECAUTIONS IMPORTANT 1. For installation only in locations not accessible to the general public. 2. Unit can be operated up to a maximum of 10,000 feet (3048 m). 3. To prevent premature heat exchanger failure, the input to the appliance, as indicated on the serial plate, must not exceed the rated input by more than 5%.
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Page 6: Metric) Conversion Factors
SI (METRIC) CONVERSION FACTORS / UNIT LOCATION Table 6.1 - SI (Metric) Conversion Factors IMPORTANT Convert Multiply By Obtain Convert Multiply By Obtain 1. Pour installation uniquement dans des endroits non "W.C. 0.24 1.699 m³/min accessibles au public. psig 6.893 Btu/ft³... - Page 7 SI (METRIC) CONVERSION FACTORS / UNIT LOCATION Figure 7.1 - Combustible Material and Service Combustion Air Requirements Clearances Units installed in tightly sealed buildings or confined spaces must be provided with two permanent openings, one near Non-Access the top of the confined space and one near the bottom. Each Model Size 3”...
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Page 8: Unit Mounting Methods
UNIT MOUNTING UNIT MOUNTING METHODS Floor Mounted Units Determine the method of mounting that will be used. Be sure For floor installations, the floor structure must be adequately the method of unit support (suspension or floor mounting) is designed to support the live weight load of the unit and any adequate to support the weight of the unit (see Weights for base other required support structure. - Page 9 UNIT MOUNTING Table 9.1 - Floor Mounted Unit Anchor Bolt Figure 9.1 - Emplacements des boulons d’ancrage Locations pour appareil installé sur le plancher Blower Type Digit 2 Model Size (Digit 16) 86.37" 36.36" – 100/125 (219.38 cm) (92.35 cm) 86.37"...
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Page 10: Unit Lifting
UNIT LIFTING UNIT LIFTING WARNING Failure to follow proper lifting instructions and applicable safety procedures could result in property damage, serious injury, or death. Lifting should only be done by a qualified rigging company. Use ALL lifting points. Test lift to ensure proper balance and rigging. -
Page 11: Installation
INSTALLATION Duct Connection to Unit Figure 11.1 - Recommended Field Installed Discharge Duct Configurations The furnace discharge (units with Model Digit 2=B) is designed to accept straight ductwork (see Figure 11.1). PROVIDE LEAK TIGHT ACCESS PANELS The blower section end and bottom openings (all units) and IN SIDE OF DISCHARGE DUCT FOR TURNING VANES HEAT EXCHANGER INSPECTION... -
Page 12: Venting
INSTALLATION VENTING For units vented as Category I, refer to Table 12.2 for vent sizing. Vent sizing for units vented as Category III are WARNING covered in a later section on page 14. Do not use a vent pipe smaller than the size of the outlet or vent transition of the appliance. - Page 13 INSTALLATION 12. Use a listed vent terminal to reduce downdrafts and Figure 13.1 - Vertical Category I Vent System moisture in vent. 10 FEET OR LESS 13. For instructions on common venting refer to the National LISTED TO ROOF PEAK TERMINAL Fuel Gas Code.
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Page 14: Gas Connections
INSTALLATION Additional Requirements for Horizontally Vented GAS CONNECTIONS Category III Units WARNING Seal all seams and joints of ungasketed single wall pipe with a metallic tape or silastic suitable for temperatures up to 350°F. (3M aluminum foil tapes 433 or 363 are 1. - Page 15 INSTALLATION Figure 15.2 - Recommended Sediment Trap/Manual Installation of piping must conform with local building Shut-off Valve Installation - Side or Bottom Gas codes, or in the absence of local codes, with the National Connection Fuel Gas Code, ANSI Z223.1 (NFPA 54) - Latest Edition. In Canada, installation must be in accordance with CAN/ CGA-B149.1 for natural gas units and CAN/CGA-B149.2 GROUND...
- Page 16 INSTALLATION Table 16.3 - Burner Orifice Sizing and Gas Table 16.1 - Gas Pipe Capacities - Natural Gas j Consumption Capacity in MBH by Nominal Pipe Diameter Pipe Gas Type Model Orifice Length (ft) 1∕2” 3∕4” 1” 1 1∕4” 1 1∕2” 2”...
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Page 17: Manifold Pressure Adjustment
Proceed to the section on this page titled "Selection of the Proper High Altitude Kit". The standard ratings for Models DBG/DCG and DBP/DCP Equation 17.1 - Manifold Pressure for Gas Heating are certified for elevations up to 2000 feet above sea level. -
Page 18: Electrical Connections
INSTALLATION junction box and one in the electrical section of the unit. ELECTRICAL CONNECTIONS Refer to this diagram for all wiring connections. WARNING External electrical connections to be installed include: • Supply power (120, 208, 240, 480, or 600 volts). •... - Page 19 INSTALLATION FOR UNITS WITH MODEL DIGIT 12=9 (MODINE • Space CO2 Sensor CONTROL SYSTEM OPTION): Some field wiring to the This sensor is required on all units that have demand factory terminal strip may include terminal strip connections based ventilation control based on space CO2 that are designed to clamp down on the wires.
- Page 20 INSTALLATION Models with Optional Cooling Coils Direct Expansion (DX) Piping The refrigerant lines should be insulated to prevent warming Models with a cooling section can be provided with a factory or cooling of the refrigerant. If the suction line is allowed to be installed direct expansion (DX) evaporator, or the coil can be cooled, liquid will condense in the line and can severely damage field supplied and installed by others.
- Page 21 INSTALLATION Use a vacuum pump to evacuate the coil and any interconnecting piping that has been open to atmosphere. Measure the vacuum in the piping using a micron gauge located as far from the pump as possible (the vacuum at the pump will be greater than the rest of the system).
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Page 22: Start-Up Procedure
START-UP PROCEDURE Start-Up Procedure not function, recheck the wiring diagram. Check to insure that none of the Control Options have tripped. IMPORTANT 12. For units with a return air damper, the return air damper linkage needs to be adjusted. Refer to Damper Linkage Adjustment on page 25. -
Page 23: Main Burner Adjustment
START-UP PROCEDURE Figure 23.2 - Manifold Pressure Test Point To Adjust the Pilot Flame Create a call for heat from the thermostat. Remove the cap from the pilot adjustment screw. For location, see the combination gas control literature supplied with unit. Adjust the pilot length by turning the screw in or out to achieve a soft steady flame 3/4"... - Page 24 START-UP PROCEDURE Check/Adjust Pressure for the Modulating Valve units, the furnaces without the modulating valves are to remain at 3.5" W.C. for natural gas or 10.0" W.C. for This section only applies to units with Electronic Modulation gas propane gas. For location of regulator adjustment, refer to controls (Model Identification Digit 12=4, 7, or 9).
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Page 25: Air Shutter Adjustment
START-UP PROCEDURE Figure 25.1 - Maxitrol EXA Modulating Valve Turn outer side of motor sheave clockwise until motor sheave is fully closed. BUTTON #2 From fully closed position, turn outer side of motor sheave SUPPLY POWER TERMINALS counterclockwise until the proper number of turns open are CONTROL SIGNAL TERMINALS achieved. -
Page 26: Control Operating Sequence
START-UP PROCEDURE Control Operating Sequence no spark. After six minutes, the cycle will begin again. After three cycles, some ignition controllers lockout for IMPORTANT approximately one hour before the cycle begins again. This will continue indefinitely until the pilot flame is sensed or power is interrupted to the system. -
Page 27: Vav Airflow Limits
START-UP PROCEDURE VAV Airflow Limits If the unit was provided with a time delay relay, the blower starts after 30 to 45 seconds. If certain conditions are followed, the allowable minimum CFM Once the temperature is satisfied, both the main and pilot of the system can be extended to: valves close 100%. -
Page 28: Component Locations
COMPONENT LOCATIONS Figure 28.1 - Factory Mounted Component Locations 2. Low Gas Pressure Switch 3. High Gas Pressure Switch 4. Power Exhauster 5. Timed Freeze Protection 6. Ignition Controller 8. Control Relay 9. Diferential Pressure Switch 10. Furnace Low Voltage Terminal Strip 11. -
Page 29: Component Descriptions
COMPONENT DESCRIPTIONS All units include the standard (STD) features. The unit (2) Low Gas Pressure Switch – (OPT) must be reviewed to determine the optional (OPT) The switch monitors the gas pressure upstream of all the gas features that may have been supplied with the unit. controls and disables the ignition controller and combination (1) Discharge Thermostat/Sensor –... - Page 30 COMPONENT DESCRIPTIONS (15) Blower Low Voltage Terminal Strip – (STD) (6) Ignition Controller – (STD) The ignition controller is factory installed in the duct furnace The blower low voltage terminal strip is located in the electrical junction box with the spark ignitor and sensor located electrical section.
- Page 31 COMPONENT DESCRIPTIONS (19) Minimum Positioner – (OPT) (All Except Digit 12=9) (24) Pillow Block Bearings – (OPT) The factory installed minimum positioner is installed in the The blower bearings are factory installed in the blower section. electrical section and is used with a modulating damper actuator The blower can be provided with either spider or pillow block to set the minimum percentage of outside air.
- Page 32 COMPONENT DESCRIPTIONS Setting the Damper Limiter: The two-position damper limiter can • Modulating Damper Actuator: A modulating actuator is be factory set to prevent the outside air damper from opening provided with Air Control options GA, GD, GE, GH, (Model 100%.
- Page 33 COMPONENT DESCRIPTIONS (37) Convenience Outlet – (OPT) (39) Dirty Filter Switch – (OPT) The dirty filter pressure switch is factory installed in the blower WARNING electrical section. The switch monitors the pressure differential between the two sides of the filters. When the filters become dirty, the differential pressure increases and trips the pressure Disconnect power supply before making wiring connections switch which energizes a light on the remote monitoring panel...
- Page 34 COMPONENT DESCRIPTIONS The contactor module includes one (1) normally open auxiliary (46) Electronic Modulation Amplifier – (OPT) contact. The contact rating is 10 amps. An electronic modulation amplifier is provided factory installed in the duct furnace electrical junction box when the unit is Figure 34.1 - Motor Starter equip ped with Electronic Modulating Gas Controls (Digit 12 = 4).
- Page 35 COMPONENT DESCRIPTIONS (49) High Limit Switch (59) Unit Enable Relay and/or Cooling Interlock - (OPT) The high limit switch is factory installed in the duct furnace The control relay is factory installed in the duct furnace electrical electrical junction box. If the limit temperature is exceeded, the junction box and is used to enable the unit based on contact gas controls are de-energized.
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Page 36: General Performance Data
GENERAL PERFORMANCE DATA Table 36.1 - General Performance Data - Models With Blower Blower Style/Size Temperature Rise (°F) Model Size Minimum Maximum Btu/Hr Input j Btu/Hr Output j (Digits 4-6) CFM k (Digit 16) Size Maximum Minimum C or D 3000 100,000 81,000... - Page 37 GENERAL PERFORMANCE DATA Table 37.1 - Airflow by Air Temperature Rise jkl Air Temperature Rise Through Unit (°F) Model Btu/Hr Btu/Hr Size Input j Output j 100,000 81,000 3,750 1,875 1,500 1,250 1,071 125,000 101,250 4,688 2,344 1,875 1,563 1,339 1,172 1,042 150,000...
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Page 38: Option & Accessory Pressure Drop Data
OPTION & ACCESSORY PRESSURE DROP DATA Table 38.1 - Option & Accessory Pressure Drop Tables (in ''W.C.) 2” Filters 2” Filters Unit Size Digit 16 Permanent MERV 8 MERV 13 Unit Size Digit 16 Permanent MERV 8 MERV 13 0.02 0.02 0.04 2,593... -
Page 39: Blower Performance Data
BLOWER PERFORMANCE DATA Table 39.1 - Unit Performance Table Total Static Pressure, ''W.C. 0.25 0.50 0.75 1.00 1.25 1.50 2.00 2.50 3.00 Digit Temp. Unit Size 16 Rise BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM 0.15 0.23 0.30... - Page 40 BLOWER PERFORMANCE DATA Table 40.1 - Unit Performance Tables Total Static Pressure, ''W.C. 0.25 0.50 0.75 1.00 1.25 1.50 2.00 2.50 3.00 Digit Temp. Unit Size 16 Rise BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM RPM BHP RPM BHP RPM BHP RPM 100°F / 120°F 1852...
- Page 41 BLOWER PERFORMANCE DATA Table 41.1 - Unit Performance Tables Total Static Pressure Inches "W.C. Unit Temp 0.25 0.50 0.75 1.00 1.25 1.50 2.00 2.50 3.00 Size Digit 16 Rise CFM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM 120°F / - 3086 0.62...
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Page 42: Blower Sheave Assembly Data
BLOWER SHEAVE ASSEMBLY DATA Adjusting the Blower Drive Setting Example: Determine motor sheave turns open for a unit operating at 4000 All units include a sheave assembly indicated by Digit 19 of CFM with a design external static pressure (ESP) of 0.70"W.C. the model nomenclature. - Page 43 BLOWER SHEAVE ASSEMBLY DATA Table 43.1 - Sheave Assembly Data Blower RPM by Sheave Turns Open Setting (Approx.) Blower Type Sheave Digit 16 Digit 19 RPM Range A, B 656-1001 1001 C, D, E 978-1265 1265 1236 1208 1179 1150 1122 1093 1064...
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Page 44: Dimensions - Unit
DIMENSIONS - UNIT Figure 44.1 - Indoor Power Vented Blower Package Unit (Model Digit 2=B, Digit 16=A through H) j 30.48 30.07 51.20 OVER ROOF 6" VENT 2.17 CONNECTOR 34.00 1.36 23.07 (HEIGHT) 24.00 24.00 43.23 37.80 C (WIDTH) 17.40 9.21 10.26 (APPROX) 8.97... - Page 45 DIMENSIONS - UNIT Figure 45.1 - Indoor Power Vented Blower Package Unit (Model Digit 2=B, Digit 16=I,J,K, or L) j 147.59 30.48 30.07 50.37 36.68 OVER ROOF 41.62 29.74 6.44 6" VENT 2.17 CONNECTOR 1.36 23.07 (HEIGHT) 24.00 24.00 43.23 37.85 C (WIDTH) 17.40...
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Page 46: Dimensions - Base
DIMENSIONS - BASE Figure 46.1 - Unit Base Dimensions j (To end of unit) 0.63 2.36 0.75" Suspension Hanging Locations (Typical 4 Corners) (Inside) Suspension 24.00 Point (Inside) Suspension Suspension Point Point Lifting Lifting Point Point Return Air 4.35 Opening 1.45 j All dimensions shown are in inches. -
Page 47: Dimensions - Cooling Coils
DIMENSIONS - COOLING COILS Figure 47.1 - DX Coil Drawing l Airflow Direction Rows TOP VIEW Distributor Inlet (Liquid Line) Connection(s) (Second Inlet on Dual Coil for Right Hand Units Circuit Coils) (Digit 9 = R) Headers on opposite side for Left Hand Units SIDE VIEW FRONT VIEW Airflow... -
Page 48: Weights
WEIGHTS Table 48.1 - Unit Weights j Base Unit Dampers Insulation Double Wall Liners Blower Digit 2 Digit 2 Digit 2 Type Fresh Air Fresh & Model Size (Digit 16) Motor Filters Only Return Air 100/125 150/175 200/225 250/300 E,F,G, or H 250/300 I, J, or K 350/400... -
Page 49: Maintenance
MAINTENANCE Blower Assembly WARNING The blower assembly includes the bearings, drive sheaves and belts. Blower bearings should be checked and lubricated based When servicing or repairing this equipment, use only on the blower manufacturer’s recommendations. Bearings factory-approved service replacement parts. A complete should also be checked for any unusual wear and replaced if replacement parts list may be obtained by contacting Modine needed. -
Page 50: Cooling Coil Maintenance
MAINTENANCE Cooling Coil Maintenance Duct Furnace Periodically, inspect the coil for signs of corrosion When providing annual maintenance for the duct furnace, keep and leaks. Repair and replacement of the coil and the the unit free from dust, dirt, grease and foreign matter. Pay connecting piping, valves, etc., must be performed as particular attention to: needed by a qualified technician. -
Page 51: Gas Piping & Controls
MAINTENANCE Gas Piping & Controls Burner and Pilot Assembly Removal The gas valves and piping should be checked annually for To remove the burner (Refer to Figure 51.2) general cleanliness and tightness. Disconnect the pilot supply line from the gas valve. The gas controls should be checked to insure that the unit is Disconnect the ignition cable from the ignition controller operating properly. -
Page 52: Service & Troubleshooting
SERVICE & TROUBLESHOOTING WARNING ATTENTION When servicing or repairing this equipment, use only Ne tentez pas de réutiliser un composant mécanique ou factory-approved service replacement parts. A complete électrique qui a été mouillé. Ces composants doivent être replacement parts list may be obtained by contacting Modine remplacés. - Page 53 SERVICE & TROUBLESHOOTING Troubleshooting (continued) Trouble Possible Cause Possible Remedy Flashback Too much primary air. Reduce primary air. Main pressure set too high. Adjust to a maximum of 14” W.C. Orifice too large. Check orifice size with those listed on the serial plate.
- Page 54 SERVICE & TROUBLESHOOTING Figure 54.1 - Lifting Flame Condition Figure 54.2 - Floating Flame Condition Figure 54.3 - Flame Rollout Appearance 5-565.6...
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Page 56: Start-Up Checklist
START-UP CHECKLIST INDIRECT GAS-FIRED HEATING EQUIPMENT Job Name: Date: Address: Model No.: City & State: Order No.: Start-Up Check List “ALL ITEMS MUST BE CHECKED” Serial No.: 1. All shipping straps, braces, tie downs removed? ____ Yes ___ No 2. Unit installed level and secure? ____ Yes ___ No 3. -
Page 57: Model Designations
MODEL DESIGNATIONS Model Identification Replacement Parts Ordering Duct furnace/make-up air units contain an ETL/ETL Canada When servicing, repairing or replacing parts on these units, certified indoor duct furnace. This duct furnace is combined locate the model identification plate of the unit and always give with either a blower section or a blower and cooling section to the complete Model Number and Serial Number from the model make a complete make-up air or heating/ventilating/ cooling... -
Page 58: Model Nomenclature For System Units
MODEL NOMENCLATURE FOR SYSTEM UNITS Indoor Heating/Make-Up Air Unit Model Nomenclature 4 5 6 20 21 1 - Product Type (PT) 15 - Transformer (TR) D or I - Indoor Indirect Fired Heating & Make-Up Air Unit 1 - 40 VA 4 - 250 VA 2 - 75 VA 0 - None... - Page 59 THIS PAGE INTENTIONALLY LEFT BLANK 5-565.6...
- Page 60 Modine Manufacturing Company 1500 DeKoven Avenue Racine, WI 53403 Phone: 1.800.828.4328 www.modinehvac.com © Modine Manufacturing Company 2023...
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